§1. Bulletproof glass, shaped charges, and the armor arms race [00:00]
Here are some other structural materials. Here's bulletproof glass — four layers, three of which are glass adhesively bonded in between. It's very important how you put the adhesive in. You don't want bubbles, because you're supposed to be transparent — you don't want to be looking through bubbles. One layer is polycarbonate, the toughest plastic known. Polycarbonate by itself used to be bulletproof glass, but we have better bullets now, so it's basically a composite. This is made by a company called PAS, Protective Armor Systems, out in western Massachusetts. They make a five-and-a-quarter-inch version with about six layers, which goes on the windows of the president's car. The thicker one will stop an RPG — a rocket-propelled grenade. That's like the shaped charges they used in Iraq.
I should have brought my shaped charge — I have one in my office. Maybe I'll bring it tomorrow. A shaped charge can typically go through about three feet of steel. I've seen the steel that a shaped charge went through. I used to be on the advisory board for the Army Materiel Command down at Aberdeen Proving Ground, where they test shaped charges. Back in the mid-80s they had developed shaped charges to the point where they could go through virtually any armor that was around. One of my former students working for the Army told me the story: they lined up three old tanks on the battlefield and shot a shaped charge through all six layers of armor — one side of armor, second tank, all the way through. An armored general tossed his cookies right there on the battlefield when he saw what a shaped charge could do. Within a year there was no shaped charge that couldn't be defeated by the improved armor, which was basically ceramic armor.
The shaped charge is basically a liquid metal jet of copper that eats right through the steel at near the speed of sound. If you put ceramic in there, the copper doesn't react with the ceramic, and so it doesn't destroy it. Now there's all kinds of different armors — it's proliferating, it's gotten very complex, and they're using supercomputers to model these things. One of the things they developed: depleted uranium, basically a half-inch diameter rod 36 inches long, fired at a target. When it hit the armor, the stresses in it would get to 300, 400 thousand psi, and most materials would fracture.
So one way to defeat depleted uranium penetrators would be to have an explosive layer on the surface of the armor. As soon as the projectile hits, it explodes, sending a shockwave through the penetrator which multiplies the stress, and the whole thing shatters — you'd have 500 ksi, above the yield strength. When I first went there in the late 80s, they were working on modeling. They were going to send one projectile in to hit the surface and set off the explosive, and another one in the same shell following right behind it at 4,000 feet per second, because the surface can't explode twice — the second one just follows the hole the first one hit. It's like sending a fullback in with blocking for the halfback behind you. The armor technology is actually pretty amazing how sophisticated it is.
[Tom holds up a composite cutting tool.] This is actually a composite material — a big heavy chunk of steel, with tungsten carbide brazed on the end, and the very tip is sintered diamond. It looks black because it's a bunch of diamond powders sintered together. It's a double-step braze. This is to reclaim asphalt on the highway. In the middle of the night they're taking the asphalt off and resurfacing. A machine comes along with a bunch of these — a big auger — and it breaks up the old asphalt and throws it in the truck, and the truck takes it back to the asphalt plant to be re-melted and recycled. The problem is the tips get a lot of abrasive wear, and the tungsten carbide, which is one of the hardest materials we have, basically wears out. You'd like it to last for an eight-hour shift, but they don't always.
Someone developed a big chunk of tungsten carbide with sintered diamond at the very tip, and these would last significantly more than an eight-hour shift. Someone asked me to evaluate the technology, because one company was considering investing in buying this other company's brazing technology. It's a good technology, but it turns out it was uneconomical — the cost of the sintered diamond was so high that getting another factor of two in life was not sufficient. Sintered diamond's not cheap. So that one didn't work out. It worked out technically but not economically.
§2. Material cost over vehicle life: ships to spacecraft [07:48]
We were talking about the relative cost of material in a structure over the life of the vehicle. For ships it's only twenty cents a pound, or for railroads — the basis is you're going to use these for 30 years. For an automobile, you typically get a hundred thousand miles, and it's two dollars a pound when you have gasoline at four dollars a gallon. Aircraft, it's a hundred thousand hours. And spacecraft it's twenty thousand dollars a pound in orbit. SpaceX and the reusable rockets hope to get the price down to five or ten thousand dollars a pound in orbit. So when you hear aerospace engineers talk about colonizing the moon at five thousand dollars a pound for what we have to move up there, just start figuring out what the tickets have to cost. We're going to have graded tickets for people who are lighter weight than others.
You can also look at the total market size just in the United States, and you see why automobiles drive things so much, and why Toyota taking over a significant fraction of the automotive market was so important. When I was living in Japan in the mid-80s, twenty-five percent of the Japanese industrial economy was based on Toyota and Nissan in the automotive market — a tremendous amount of their economy. And that's just 30 million cars in the United States. Aircraft — Boeing is a very important contributor to our export market, but it's relatively small compared to other things. The whole spacecraft industry is also relatively small, very high-tech materials. You read about these things in the Wall Street Journal and other popular magazines to tell you how wonderful these materials are, and they are very intriguing, but in terms of general economics, let's go to the big bucks. The big bucks are in more mundane materials.
Historically, where the United States has spent its efforts: this is a very nonlinear time scale. The industrial revolution of the 1800s to 1950 is over. The red is the industrial sector, and right after World War Two we were in our heyday. We'd bombed out the rest of the world's industrial sectors and we really were the world's industrial powerhouse. There's that famous story of the American Secretary of State, and the Japanese ambassador says, "Mr. Secretary, Japan would like to export some products to the United States" — this is in the 1950s. And the US Secretary of State says, "Well, Japan doesn't make anything that we would want." In 1950 that might have been true, but the Japanese started learning to make steel and ships and automobiles.
The manufacturing sector has decreased. The service sector has increased — it was nothing back in the 1850s to speak of. The big sector back in the 1800s was agriculture. In 1800 about ninety-five percent of the workforce was engaged in just feeding themselves. Now that might have included distribution of food, but most of them were out there growing crops. That's why things like Cyrus McCormick's wheat harvester in the 1830s was such an important invention — because so many people were out there cutting wheat by hand. The cotton gin by Eli Whitney — those things were important because they allowed industrialization. Now we have the growth of the service sector, and another growing sector of government and welfare transfer payments, which is going to change the whole economic reality of our country in the world.
§3. Materials as ten percent of fabricated cost [13:07]
Fabricated cost as a fraction of the cost of structural materials. As much as materials scientists like to say "oh, materials are wonderful," materials are a relatively small fraction of the fabricated cost. The raw materials as a percent of the total cost is only ten or twenty percent of the actual final manufactured cost. Design is roughly the same. Fabrication, which is mostly manufacturing — what most people relegate to the mechanical engineers — is roughly double the material costs. Inspection and testing and quality control, which at MIT is over in the Sloan School, and non-destructive testing, which we don't even talk about much, is equal to the material cost. And G&A management is about ten percent. You add all this up and you could either lose money or make money depending on how it all fits together.
One of the examples, referenced in the paper "Materials for the 21st Century," is a study done by the US Navy. Aircraft carriers gain about 250 tons a year. If you look at the last 50 years, you take the Nimitz-class carrier — they built a new carrier every one or two years, so we've had twenty-some carriers since the Nimitz, all the way up to a new whole class now. The Nimitz hull design went for about 50 years, and if you look at the weight of the Nimitz, which is in the 60,000-ton class, to whatever the last carriers were, which are up to about one and a half times that, the average weight gain on an aircraft carrier was 250 tons a year. Most of it unfortunately is up in the superstructure or near the top deck, instead of the aircraft deck, and that's a problem for stability. So the Navy was looking at going to a higher-strength steel for the hull. They were going to go to an HSLA 60, and they wanted to know what the cost savings might be.
That particular steel is a higher-quality plate, and it might cost you two thousand dollars a ton, or a dollar a pound. I gave you a price of steel before — somewhere around 20 to 40 cents a pound, four hundred dollars a ton. Well, this stuff is going to be two thousand dollars a ton. They did about a million-dollar study at Newport News Shipbuilding and Dry Dock to find out what the as-fabricated cost would be, and they found it was going to be about ten thousand dollars a ton, or ten times as much. There's my ten percent again. I could have done that study for them for half a million rather than a million. The general rule of thumb I've worked out over the years is about ten percent of the cost of a fabricated product is the material cost.
So what does that mean for a Ford Taurus or a Toyota Camry that sells for 25 grand? There's only twenty-five hundred dollars worth of material in that car. However, if you go from steel to aluminum, there's an increase in cost because the aluminum is more expensive, and you might add three hundred dollars worth of material to the cost of that car. What's the big deal of going to an all-aluminum vehicle? Well, it turns out all these other things for the aluminum can increase that cost by five or ten thousand dollars. So it's not just going from a twenty-five-thousand-dollar car to a twenty-five-thousand-five-hundred-dollar car. It's going from a twenty-five-thousand-dollar car to a thirty-thousand-dollar car when you go to an all-aluminum vehicle. Audi 25 years ago came out with all-aluminum structures, but that was for $80,000 vehicles.
This ten percent figure has some variation. There are two areas where the cost of the raw material is thirty percent of the cost of building something. One is pipelines — like the Keystone pipeline from the Canadian border down to Texas — the steel pipe is going to be thirty percent of the cost of digging the hole, putting it in the ground, and everything else. The other is utility transmission towers — these big ugly things that have half-million-volt electrical lines on them.
§4. The Ford F-150 and the aluminum vehicle [18:30]
First of all, they picked the highest-volume vehicle in the world, so there's a certain economies of scale that dropped the price a little bit. But how they're making it work is they worked for 30 years on joining techniques. The real problem for aluminum is the joining technology. I passed around the thing that had steel rivets — they have steel rivets because not everything on that F-150 is aluminum. They have to join aluminum to steel, and how do you do that without having a serious corrosion problem because of the galvanic action and the salt on the roads? There's 30 years worth of development. I first started seeing it back in the early 90s when I would visit Detroit and see them in the research labs working on joining techniques and corrosion protection, and it wasn't until 20 years later that they came out with an all-aluminum F-150.
In the early 90s I used to say we didn't know how to build an all-aluminum vehicle — we had the Duesenbergs and JP Morgan's Pierce-Arrow in the 1930s, but these were very expensive vehicles. We didn't know how to build a twenty-five-thousand-dollar Ford Taurus in aluminum that would sell for $25,000. We still don't know how to build a thirty-thousand-dollar F-150, but we do know how to build a 35,000-dollar F-150. We brought the fabrication cost down. They amortized a lot of the design and engineering over the largest vehicle production volume in the world. Plus to a certain extent they're hoping to keep their market share, and they may have taken a hit to a certain extent.
The aluminum companies were never quite ready to invest in the production capacity needed for the sheet material until one of the automotive companies committed to a large vehicle platform. A lot of the growth in the aluminum business in the last two or three years is because Ford made the commitment to build an all-aluminum high-production vehicle. The amount of aluminum Audi used could be important to an aluminum company, but it's not going to change their product mix percentages. When you go to a Ford F-150 with 800,000 vehicles a year, it makes a difference.
In fact Ford didn't want to do it if there was only one aluminum supplier. That's another thing in the 600-billion-dollar automotive industry. GM and Ford will not commit to using a new material if there's only one supplier. If you've got a monopolistic position, they'll thumb their nose at you, because they know what you're going to do to them. If you've got a monopoly hold on them, and they design it into a new vehicle, all of a sudden, "oh, our costs have gone up," and to them it's all their profit. You would steal ten billion dollars worth of profit. So they want multiple suppliers. That's another externality in the automotive business.
The other thing GM is very careful of is avoiding lawsuits. There are people out there who will try to get something into GM and claim that GM made a commitment, and then GM will say no we didn't make a commitment, and they'll sue GM for billions of dollars for restraint of trade or whatever they call it. GM is very gun-shy of that because they've had some very expensive lawsuits. Other questions?
§5. Transmission towers, the Hubble, and material cost ratios [23:18]
So pipelines, transmission towers — I'm just finishing up a project for a million tons of steel for transmission towers, a 1.3-billion-dollar purchase of steel to build the transmission towers. That's thirteen hundred dollars a ton for galvanized steel. Automotive and aircraft, it's about ten percent. Spacecraft, it may be down around two percent. Semiconductors — obviously that's not a structural material, and the actual material cost is relatively low.
Student: [question about spacecraft material costs]
Space junk — because it's all engineering and fancy composites. This is twenty-thousand-dollar-a-pound material as fabricated. The material itself only costs twelve thousand dollars a pound as fabricated into the structure. But the actual material weight in the structure, the cost is only two percent of that. Even though you're using carbon fiber composites, the material costs — which for an automobile would be ten percent — for a spacecraft, the inspection and testing goes way up.
Think of the Hubble telescope. The Hubble had a few design problems on the mirrors, and they had a two-billion-dollar project that all of a sudden could have been junked if it hadn't been for Lincoln Lab developing a military technology to compute away the distortions of the atmosphere. One of the reasons for putting the Hubble telescope up in space was to get rid of atmospheric distortions. Well, they put it up there and found they had distortions in their mirror. We'll never build another Hubble telescope to do optical imaging in space, because now, because of places like MIT Lincoln Lab, they can shoot a laser beam through the atmosphere, measure the distortion, and back-calculate. There's a satellite up there measuring the distortion of the beam going through the atmosphere, and they can now take pictures from Earth through the atmosphere that are just as accurate as the Hubble telescope, because they do computer correction for the distortions. So we will never need to build another Hubble telescope.
But why did they do that? Well, if you want to read the president's golf card and what his score is from a hundred miles in space, you've got it. See if he's cheating on his golf score. That answer your question? Okay.
Student: I have a question about steel for transmission towers versus wood.
I'm not talking about the ones that are taking 10,000 volts down the street to a transformer. I'm talking about the half-million- to million-volt transmission towers that are 100 to 150 feet tall — the big utility transmission towers. The other ones they call distribution towers. They have a hierarchy of terms. Transmission towers are when you transfer five hundred to a thousand miles, and distribution is when you're trying to do 10 miles down the road from some power transformer base. When I was a kid the wood would last 30 or 40 years; now they've got treatments for the wood and it never rots in a hundred years. The wood stuff has gotten better, but they're still ugly, and if you can afford it you'd rather bury it in the ground and have a neighborhood that doesn't have a bunch of wires all over everywhere. There's a famous old picture of New York City with all the telephone wires around 1900 — nothing but telephone wires in the street. Okay, other questions?
§6. What you can afford at each price tier [27:48]
So we went through that. If we want to talk about materials as a percent of the total manufacturing costs, whether it's ten or twenty percent: if steel costs four hundred dollars a ton, you can actually afford to make ships and railroads out of it, but you barely can. These are the materials that are cheap enough to make ships or railroad cars. If you're willing to go to twenty percent, we do make aluminum railroad cars because they're lighter weight, and you're pulling all that weight around. Automobiles at ten percent at steel; at 20 percent you can use aluminum and plastics, although you have a hard time using some of the plastics, but we'll talk about that later. They've built the BMW i3 and i7 with graphite fiber — we can talk about how they did that. That was a student's presentation in this class, the BMW i3. He had studied this for some time — he was a BMW employee, an LGO student. He explained how they could beat this thing, but you start loading up the i3 and it's a sixty-thousand-dollar vehicle, and the i7 is a hundred-thousand-dollar vehicle. So it's like the all-aluminum Audi. The first ones that come in are on the high end of the scale.
Aircraft, aluminum for years, and now we're switching over to composites. What limited the composites was the fabricability — could they repair them? The American Airlines jet that landed in Brooklyn when it took off out of Kennedy — they had repaired the empennage. They had problems in production and they repaired the empennage, and that was actually a student's presentation. I can't remember the flight. Was it due to pilot error or due to the composite repair? People are still on both sides of that. Spacecraft, you can certainly afford composites, and you can even afford some refractory metals like beryllium that are horrendously expensive. It also depends on your economic class. Some people in the Ozarks will build their houses out of wood, and other people in the Hamptons or Martha's Vineyard will build them out of whatever they care about. There's a big example right now of people building 20-million-dollar mega-mansions on Martha's Vineyard.
§7. Sprague's law and the boutique materials trap [31:27]
One of the people I like to quote is Robert Sprague, who was materials manager for GE Aircraft Engines in Cincinnati. He said: whenever you first hear about the properties of a new material, write it down, because those are the best properties the material will ever have. He said that 30 or 40 years ago, and he said that with a lot of experience. And Jim Williams, who replaced him — he was dean of engineering at Ohio State, and then went back there after a while — he had a corollary: whenever you first hear about the cost of a new material, write it down, because that's the lowest cost it will ever have. New materials' properties always degrade with time, and their cost always increases with time. So be careful about claims for new materials.
Another thing people do with new materials is they'll be very careful about how they phrase the properties. The example I like to give was Professor Gary Wnek, who was an assistant professor in this department. He left before tenure ever came. He was really a chemist but he worked on polymers. This was back 25, 30 years ago when electrically conductive polymers were a new thing. He was giving a talk in the Chipman Room about his research on electrically conductive polymers. At the time the polymer was polyacetylene. Ordinarily polymers are covalently bonded — there's no free electrons, and that's why they're excellent insulators. Polyacetylene has a bunch of double bonds, and so properly doped, it can have some free electrons and so is electrically conductive. He was pointing out that the specific electrical resistivity of polyacetylene was better than copper, and therefore big rotor generators and rotating machinery and motors would all be using polyacetylene or other conductive polymers in the future. I thought, wow, that's pretty impressive.
Until the next morning, when I was shaving — all of a sudden I realized: wait a second. Today aluminum has a better specific electrical conductivity than copper, but we still wind those motors and generators out of copper. Why? Even though it's spinning at a very high rate of speed, we need the lowest electrical resistivity. We don't need the lowest specific electrical resistivity. What was he doing? He was dividing by the density. Because polymers have a low density, their specific electrical resistivity was better than copper. But that was not the figure of merit for rotating equipment. It was the lowest electrical resistivity. The only element on the periodic table that's better is silver. Why don't we use silver? Because it's a hundred times more expensive than copper. So there is a cost consideration, but it's a factor of a hundred.
In fact during World War Two at Oak Ridge National Lab they used big magnets to separate uranium. They had basically a great big mass spec, and they would separate the fissile uranium from the non-fissile uranium isotopes — U-238 versus U-235. They had uranium hexafluoride vapors running around in a circle, and they would separate out the lighter ones. Copper was in very short supply during World War Two, so they wound their magnets out of silver from the US Mint in Philadelphia. After the war they had to return the silver to the US Mint, but nothing happened to it other than being fabricated into wire. Silver is better. Yes?
Student: [inaudible — skepticism about the Sprague quote]
You can disbelieve it — it's not my quote. I'm just propagating it.
It's definitely got a better — as a structural material? It's a functional material. We're talking about structural materials that go in engines. You have to recognize where they're coming from. In the jet engine business, people come in with fancy composites or some new metal alloys that are supposed to be higher temperature or whatever, and things always end up never quite having the properties they wanted. You're talking about something still on the learning curve where we're seeing tenfold reductions in price every five years. That's a different maturity. These are further down the maturity curve. It's not true for every material, but there's some wisdom to what they say, certainly in their industry.
That was the problem with polyacetylene electrical conductors — they oxidize in the air within minutes. So as long as you want to run your generator in an argon atmosphere or a vacuum, it's fine. They don't always mention some of the Achilles heels these things have. The perovskites are a good example — they don't have the stability. If someone comes along with a breakthrough to improve that stability, then they may take over. They've got certain beneficial properties.
Jim Williams used to coin the term "boutique materials." The reason he called them boutique is, for some of these materials there's going to be a market of a thousand pounds a year. Who's going to make it? What company is going to invest in some super-duper material if there's only a thousand pounds a year? There's a market volume issue here too, not just what you can make in a laboratory. Part of the point is people will claim all kinds of things for what they can make in a laboratory, and they can be very interesting from a scientific point of view. From an engineering point of view it's crap.
In general one out of 20 companies will be successful — 19 will fail for every one that's successful. The other thing about materials, which is not really something I came up with — most people credit a paper I wrote in 1995 that I didn't quote who I heard it from — but it takes 20 years to bring a new material to market. I gave you that 1995 paper in Technology Review on bringing new materials to market. At the time it was the most-requested article ever in Technology Review, because everybody was excited about new materials. In there I talked about the problems of bringing new materials to market.
The point really is not necessarily what they say about their class of materials. It's really about: be very cautious when people start making claims about new materials.
§8. Molten Metal Technologies: a cautionary tale [40:44]
Student: [question about energy density claims]
How are you going to raise your money unless you've got the best, right? I'll give you an example that really bugs me no end, because I'm a steel guy. There was a guy in chemical engineering who graduated from MIT, went to work for US Steel, and he learned that molten steel is a universal solvent, just like water is a universal solvent for lots of things. Molten iron is a wonderful high-temperature universal solvent. So he decided he was going to throw a lot of environmental waste into steel, and it would just dissolve, and then we could sell the steel. He gave this idea to US Steel, and the people at US Steel were not stupid. They looked at it and said, if you want it, you can have the patent.
Well, that did not deter him. He patented it, came to MIT, got together with the head of our Technology Licensing Office, a guy named John Preston, and they started marketing this as the solution to the world's pollution problems — we could throw everything into a bath of molten steel. They called it Molten Metal Technologies. They raised 130 million overnight. These two guys were worth 25 million apiece. When Vice President Gore was talking at MIT at Kresge Auditorium, John Preston, head of the Technology Licensing Office, was in charge of putting together the program with panelists about new technologies. Who did he put on as one of the four panelists, other than Chris — the guy who came up with the patent? Don Sadoway and I said, "Hey, wait a second, seems like a little conflict of interest here. You're using your position at MIT to..." We actually called up the Vice President for Research and said, hey, little conflict of interest here. And MIT in their great wisdom and high integrity said, "Oh, MIT's got a piece of this action, so we don't think there's a problem." It's a true story.
Sadoway and I said okay — same types of crooks in the administration. There were a few problems with the technology. There's an element that will destroy steel refractories called sodium. Do you think there's any sodium in most of the waste streams? If you want to throw garbage, there's sodium all over. It's a couple percent of the ocean, and it's in all kinds of other things. You would destroy all your steelmaking technology. They built a plant down south of here, and there were several very distinguished faculty members, department heads and others, who were on the board of directors and had pieces of this company. I was deathly afraid that someday this was going to come, and MIT was going to get a big black eye when all the chickens came home to roost. People were saying this is wonderful. I was giving a talk back when we had what's called LFM, before LGO, and someone asked me before class what I thought of Molten Metal Technologies, because it was all over the Wall Street Journal — this wonderful MIT technology. I can't remember how I phrased it, but I basically did not say anything complimentary about it.
It turns out the student was asking because his father was an investor and was thinking about investing. I said, don't — this is pure crap, if they knew anything about steel technology. There's another element called chlorine. You know what happens when you put chlorine into a steel furnace? You get phosgene gas, COCl₂. Phosgene gas is one of the gases they used in World War One to gas people. It's toxic. So Chris and John knew nothing about this. The MIT professors who were making some money off this new startup — I don't know if they knew anything about it. I tried to say some things about it. There's a famous quote I made: once you read about it in the Wall Street Journal, it's no longer news. So don't do your investing based on what you read in the Wall Street Journal, because everywhere, all the other investors are reading that same thing that same day.
They were going to get a 30-million-dollar contract from the Department of Energy to get rid of radioactive waste. Wait a second — you're going to throw radioactive waste into a big steel bath, and somehow it's going to transmute those nuclei into a non-radioactive form? This is new science here, folks. But they were getting 30 million dollars from your government and my government, part of our tax money. How bad is the science, right? About three years later, they were indicted. Fortunately MIT's name was not in the article — the newspaper didn't list MIT as a startup. So some of these things get really nasty. Be careful, try to find somebody who knows what they're talking about.